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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

[Now, The Time for Probes and In-Situ Science]

A viewgraph explaining the need for probes and in situ measurements to understand data from extra solar planet studies is shown. The topics include: 1) To explore the universe and search for life: Probes in Context; 2) What is a probe?; 3) NASA Ames Research Center-founded 1939; 4) Past & Present: Successful Probes and Fly-by's; 5) Thermal Protection Materials and Arc-Jet Facility; 6) Mars Exploration Rovers-Spirit & Opportunity; 7) Bio/Info/Nanotechnology; 8) Technology for Exploration; 9) Award Winning NASA Research Park; 10) Where we need to go; and 11) The Future: Pico Probes

Hubbard, G. Scott↗
NASA NTRS2007

Emissivity Results on High Temperature Coatings for Refractory Composite Materials

The directional emissivity of various refractory composite materials considered for application for reentry and hypersonic vehicles was investigated. The directional emissivity was measured at elevated temperatures of up to 3400 F using a directional spectral radiometric technique during arc-jet test runs. A laboratory-based relative total radiance method was also used to measure total normal emissivity of some of the refractory composite materials. The data from the two techniques are compared. The paper will also compare the historical database of Reinforced Carbon-Carbon emissivity measurements with emissivity values generated recently on the material using the two techniques described in the paper.

Ohlhorst, Craig W.↗
NASA NTRS2008

Ongoing Capabilities and Developments of Re-Entry Plasma Ground Tests at EADS-ASTRIUM

During re-entry, spacecrafts are subjected to extreme thermal loads. On mars, they may go through dust storms. These external heat loads are leading the design of re-entry vehicles or are affecting it for spacecraft facing solid propellant jet stream. Sizing the Thermal Protection System require a good knowledge of such solicitations and means to model and reproduce them on earth. Through its work on European projects, ASTRIUM has developed the full range of competences to deal with such issues. For instance, we have designed and tested the heat-shield of the Huygens probe which landed on Titan. In particular, our plasma generators aim to reproduce a wide variety of re-entry conditions. Heat loads are generated by the huge speed of the probes. Such conditions cannot be fully reproduced. Ground tests focus on reproducing local aerothermal loads by using slower but hotter flows. Our inductive plasma torch enables to test little samples at low TRL. Amongst the arc-jets, one was design to test architecture design of ISS crew return system and others fit more severe re-entry such as sample returns or Venus re-entry. The last developments aimed in testing samples in seeded flows. First step was to design and test the seeding device. Special diagnostics characterizing the resulting flow enabled us to fit it to the requirements.

Jullien, Pierre↗
NASA NTRS2007

Ceramic Paste for Patching High-Temperature Insulation

A ceramic paste that can be applied relatively easily, either by itself or in combination with one or more layer(s) of high-temperature ceramic fabrics, such as silicon carbide or zirconia, has been invented as a means of patching cracks or holes in the reinforced carbon-carbon forward surfaces of a space shuttle in orbit before returning to Earth. The paste or the paste/fabric combination could also be used to repair rocket-motor combustion chambers, and could be used on Earth to patch similar high-temperature structures. The specified chemical composition of the paste admits of a number of variations, and the exact proportions of its constituents are proprietary. In general, the paste consists of (1) silicon carbide, possibly with addition of (2) hafnium carbide, zirconium carbide, zirconium boride, silicon tetraboride, silicon hexaboride, or other metal carbides or oxides blended with (3) a silazane-based polymer. Because the paste is viscous and sticky at normal terrestrial and outer-space ambient temperatures, high-temperature ceramic fabrics such as silicon carbide or zirconia fabric impregnated with the paste (or the paste alone) sticks to the damaged surface to which it is applied. Once the patch has been applied, it is smoothed to minimize edge steps as required [forward-facing edge steps must be < or equal to 0.030 in. (< or equal to 0.76 mm) in the original intended space-shuttle application]. The patch is then heated to a curing temperature thereby converting it from a flexible material to a hard, tough material. The curing temperature is 375 to 450 F (approx.190 to 230 C). In torch tests and arc-jet tests, the cured paste was found to be capable of withstanding a temperature of 3,500 F (approx. 1,900 C) for 15 minutes. As such, the material appears to satisfy the requirement, in the original space-shuttle application, to withstand re-entry temperatures of approx.3,000 F (approx. 1,600 C).

Adam, Steven J.↗
NASA NTRS2007

Creep Forming of Carbon-Reinforced Ceramic-Matrix Composites

A set of lecture slides describes an investigation of creep forming as a means of imparting desired curvatures to initially flat stock plates of carbon-reinforced ceramic-matrix composite (C-CMC) materials. The investigation is apparently part of a continuing effort to develop improved means of applying small CCMC repair patches to reinforced carbon-carbon leading edges of aerospace vehicles (e.g., space shuttles) prior to re-entry into the atmosphere of the Earth. According to one of the slides, creep forming would be an intermediate step in a process that would yield a fully densified, finished C-CMC part having a desired size and shape (the other steps would include preliminary machining, finish machining, densification by chemical vapor infiltration, and final coating). The investigation included experiments in which C-CMC disks were creep-formed by heating them to unspecified high temperatures for time intervals of the order of 1 hour while they were clamped into single- and double-curvature graphite molds. The creep-formed disks were coated with an oxidation- protection material, then subjected to arc-jet tests, in which the disks exhibited no deterioration after exposure to high-temperature test conditions lasting 490 seconds.

Vaughn, Wallace L.↗
NASA NTRS2010

Validation of a Three-Dimensional Ablation and Thermal Response Simulation Code

The 3dFIAT code simulates pyrolysis, ablation, and shape change of thermal protection materials and systems in three dimensions. The governing equations, which include energy conservation, a three-component decomposition model, and a surface energy balance, are solved with a moving grid system to simulate the shape change due to surface recession. This work is the first part of a code validation study for new capabilities that were added to 3dFIAT. These expanded capabilities include a multi-block moving grid system and an orthotropic thermal conductivity model. This paper focuses on conditions with minimal shape change in which the fluid/solid coupling is not necessary. Two groups of test cases of 3dFIAT analyses of Phenolic Impregnated Carbon Ablator in an arc-jet are presented. In the first group, axisymmetric iso-q shaped models are studied to check the accuracy of three-dimensional multi-block grid system. In the second group, similar models with various through-the-thickness conductivity directions are examined. In this group, the material thermal response is three-dimensional, because of the carbon fiber orientation. Predictions from 3dFIAT are presented and compared with arcjet test data. The 3dFIAT predictions agree very well with thermocouple data for both groups of test cases.

Chen, Yih-Kanq↗
NASA NTRS2010

Development of a Tool to Recreate the Mars Science Laboratory Aerothermal Environment

The Mars Science Laboratory will enter the Martian atmosphere in 2012 with multiple char depth sensors and in-depth thermocouples in its heatshield. The aerothermal environment experienced by MSL may be computationally recreated using the data from the sensors and a material response program, such as the Fully Implicit Ablation and Thermal (FIAT) response program, through the matching of the char depth and thermocouple predictions of the material response program to the sensor data. A tool, CHanging Inputs from the Environment of FIAT (CHIEF), was developed to iteratively change different environmental conditions such that FIAT predictions match within certain criteria applied to an external data set. The computational environment is changed by iterating on the enthalpy, pressure, or heat transfer coefficient at certain times in the trajectory. CHIEF was initially compared against arc-jet test data from the development of the MSL heatshield and then against simulated sensor data derived from design trajectories for MSL. CHIEF was able to match char depth and in-depth thermocouple temperatures within the bounds placed upon it for these cases. Further refinement of CHIEF to compare multiple time points and assign convergence criteria may improve accuracy.

Beerman, A. F.↗
NASA NTRS2011

Two-Dimensional Finite Element Ablative Thermal Response Analysis of an Arcjet Stagnation Test

The finite element ablation and thermal response (FEAtR, hence forth called FEAR) design and analysis program simulates the one, two, or three-dimensional ablation, internal heat conduction, thermal decomposition, and pyrolysis gas flow of thermal protection system materials. As part of a code validation study, two-dimensional axisymmetric results from FEAR are compared to thermal response data obtained from an arc-jet stagnation test in this paper. The results from FEAR are also compared to the two-dimensional axisymmetric computations from the two-dimensional implicit thermal response and ablation program under the same arcjet conditions. The ablating material being used in this arcjet test is phenolic impregnated carbon ablator with an LI-2200 insulator as backup material. The test is performed at the NASA, Ames Research Center Interaction Heating Facility. Spatially distributed computational fluid dynamics solutions for the flow field around the test article are used for the surface boundary conditions.

Dec, John A.↗
NASA NTRS2012

Thermal Analysis of Small Re-Entry Probe

The Small Probe Reentry Investigation for TPS Engineering (SPRITE) concept was developed at NASA Ames Research Center to facilitate arc-jet testing of a fully instrumented prototype probe at flight scale. Besides demonstrating the feasibility of testing a flight-scale model and the capability of an on-board data acquisition system, another objective for this project was to investigate the capability of simulation tools to predict thermal environments of the probe/test article and its interior. This paper focuses on finite-element thermal analyses of the SPRITE probe during the arcjet tests. Several iterations were performed during the early design phase to provide critical design parameters and guidelines for testing. The thermal effects of ablation and pyrolysis were incorporated into the final higher-fidelity modeling approach by coupling the finite-element analyses with a two-dimensional thermal protection materials response code. Model predictions show good agreement with thermocouple data obtained during the arcjet test.

Agrawal, Parul↗
NASA NTRS2012

Active Oxidation of a UHTC-Based CMC

The active oxidation of ceramic matrix composites (CMC) is a severe problem that must be avoided for multi-use hypersonic vehicles. Much work has been performed studying the active oxidation of silicon-based CMCs such as C/SiC and SiC-coated carbon/carbon (C/C). Ultra high temperature ceramics (UTHC) have been proposed as a possible material solution for high-temperature applications on hypersonic vehicles. However, little work has been performed studying the active oxidation of UHTCs. The intent of this paper is to present test data indicating an active oxidation process for a UHTC-based CMC similar to the active oxidation observed with Si-based CMCs. A UHTC-based CMC was tested in the HyMETS arc-jet facility (or plasma wind tunnel, PWT) at NASA Langley Research Center, Hampton, VA. The coupon was tested at a nominal surface temperature of 3000 F (1650 C), with a stagnation pressure of 0.026 atm. A sudden and large increase in surface temperature was noticed with negligible increase in the heat flux, indicative of the onset of active oxidation. It is shown that the surface conditions, both temperature and pressure, fall within the region for a passive to active transition (PAT) of the oxidation.

Glass, David E.↗
NASA NTRS2012

Real-Time X-ray Radiography Diagnostics of Components in Solid Rocket Motors

Solid rocket motors (SRMs) typically use nozzle materials which are required to maintain their shape as well as insulate the underlying support structure during the motor operation. In addition, SRMs need internal insulation materials to protect the motor case from the harsh environment resulting from the combustion of solid propellant. In the nozzle, typical materials consist of high density graphite, carbon-carbon composites and carbon phenolic composites. Internal insulation of the motor cases is typically a composite material with carbon, asbestos, Kevlar, or silica fibers in an ablative matrix such as EPDM or NBR. For both nozzle and internal insulation materials, the charring process occurs when the hot combustion products heat the material intensely. The pyrolysis of the matrix material takes away a portion of the thermal energy near the wall surface and leaves behind a char layer. The fiber reinforcement retains the porous char layer which provides continued thermal protection from the hot combustion products. It is of great interest to characterize both the total erosion rates of the material and the char layer thickness. By better understanding of the erosion process for a particular ablative material in a specific flow environment, the required insulation material thickness can be properly selected. The recession rates of internal insulation and nozzle materials of SRMs are typically determined by testing in some sort of simulated environment; either arc-jet testing, flame torch testing, or subscale SRMs of different size. Material recession rates are deduced by comparison of pre- and post-test measurements and then averaging over the duration of the test. However, these averaging techniques cannot be used to determine the instantaneous recession rates of the material. Knowledge of the variation in recession rates in response to the instantaneous flow conditions during the motor operation is of great importance. For example, in many SRM configurations the recession of the solid propellant grain can drastically alter the flow-field and effect the recession of internal insulation and nozzle materials. Simultaneous measurement of the overall erosion rate, the development of the char layer, and the recession of the char-virgin interface during the motor operation can be rather difficult. While invasive techniques have been used with limited success, they have serious drawbacks. Break wires or make wire sensors can be installed into a sufficient number of locations in the charring material from which a time history of the charring surface can be deduced. These sensors fundamentally alter the local structure of the material in which they are imbedded. Also, the location of these sensors within the material is not known precisely without the use of an X-ray. To determine instantaneous recession rates, real-time X-ray radiography (X-ray RTR) has been utilized in several SRM experiments at PSU. The X-ray RTR system discussed in this paper consists of an X-ray source, X-ray image intensifier, and CCD camera connected to a capture computer. The system has been used to examine the ablation process of internal insulation as well as nozzle material erosion in a subscale SRM. The X-ray source is rated to 320 kV at 10 mA and has both a large (5.5 mm) and small (3.0 mm) focal spot. The lead-lined cesium iodide X-ray image intensifier produces an image which is captured by a CCD camera with a 1,000 x 1,000 pixel resolution. To produce accurate imagery of the object of interest, the alignment of the X-ray source to the X-ray image intensifier is crucial. The image sequences captured during the operation of an SRM are then processed to enhance the quality of the images. This procedure allows for computer software to extract data on the total erosion rate and the char layer thickness. Figure 1 Error! Reference source not found.shows a sequence of images captured during the operation the subscale SRM with the X-ray RTR system. The X-rayTR system, alignment procedure, uncertainty determination, and image analysis process will be discussed in detail in the full manuscript.

Cortopassi, A. C.↗
NASA NTRS2012

Closed Gap Slug Calorimeter for Plasma Stream Characterization

Slug calorimeters are used in sheer and stagnation mode to characterize heat flux levels for high enthalpy streams. The traditional design features a gap between slug and holder, which can be of concern in these convective heat flux environments. The challenge is to develop a calorimeter that closes the gap to gas flow, but largely maintains thermal insulation of the slug. The work presented herein introduces two new slug calorimeter designs featuring a closed gap. This is done using either aerogel as a filler or press fitting the slug with a disk. The designs were verified and compared to the baseline calorimeter design under radiative heat flux. Building on this, the calorimeters were exposed to convective heat flux in the arc-jet facilities. Results from the new designs and conclusions on the impact of the gap in convective heat flux will be shown.

Nawaz, Anuscheh↗
NASA NTRS2013

Ceramic Adhesive and Methods for On-Orbit Repair of Re-Entry Vehicles

This adhesive is capable of repairing damaged leading edge components of reentry vehicles while in space, and is novel with regard to its ability to be applied in the vacuum of space, and in a microgravity environment. Once applied, the adhesive provides thermal and oxidation protection to the substrate (in this case, reinforced carbon/carbon composites, RCCs) during re-entry of a space vehicle. Although there may be many formulations for repair adhesives, at the time of this reporting, this is the first known adhesive capable of an on-orbit repair. The adhesive is an engineered ceramic material composed of a pre-ceramic polymer and refractory powders in the form of a paste or putty that can be applied to a scratched, cracked, or fractured composite surface, covering and protecting the damaged area. The adhesive is then "cured" with a heat cycle, thereby cross-linking the polymer into a hardened material and bonding it to the substrate. During the heat of reentry, the material is converted to a ceramic coating that provides thermal and oxidative stability to the repaired area, thus allowing the vehicle to pass safely from space into the upper atmosphere. Ceramic powders such as SiC, ZrB2 and Y2O3 are combined with allylhydridopolycarbosilane (AHPCS) resin, and are mixed to form a paste adhesive. The material is then applied to the damaged area by brush, spatula, trowel, or other means to fill cracks, gaps, and holes, or used to bond patches onto the damaged area. The material is then cured, in a vacuum, preferably at 250F (approximately equal to 121C) for two hours. The re-entry heating of the vehicle at temperatures in excess of 3,000F (approximately equal to 1,650C) then converts this material into a ceramic coating. This invention has demonstrated advantages in resistance to high temperatures, as was demonstrated in more than 100 arc-jet tests in representative environments at NASA. Extensive testing verified oxidation protection for the repaired substrate (RCC), and confirmed that the microstructure of the resulting repair leads to durability and resistance to melting or flow. Its processability and working life in a vacuum was demonstrated by NASA astronauts in glovebox processing studies, as well as on-orbit in the open space shuttle bay. All of these advantages increase the working life of NASA vehicles, as well as improve safety for any crew on a manned vehicle. The adhesive, trademarked NOAX(TM). or Non-Oxide Adhesive Experimental, flew on all space shuttle missions from Return To Flight (STS-114) until the final flight (STS- 135) as a crack repair material for the leading edges and nose cap of the vehicle. NOAX(TM) was patented under U.S. Patents 7,628,878 and 7,888,277.

Riedell, James A.↗
NASA NTRS2013

Micromechanical Characterization and Testing of Carbon Based Woven Thermal Protection Materials

Woven thermal protection system (TPS) materials are one of the enabling technologies for mechanically deployable hypersonic decelerator systems. These materials can be simultaneously used for thermal protection and as structural load bearing members during the entry, descent and landing operations. In order to ensure successful thermal and structural performance during the atmospheric entry, it is important to characterize the properties of these materials, once they have been subjected to entry like conditions. The present paper focuses on mechanical characteristics of pre-and post arc-jet tested woven TPS samples at different scales. It also presents the observations from scanning electron microscope and computed tomography images, and explains the changes in microstructure after being subjected to combined thermal-mechanical loading environments.

Agrawal, Parul↗
NASA NTRS2013

Implicit Coupling Approach for Simulation of Charring Carbon Ablators

This study demonstrates that coupling of a material thermal response code and a flow solver with nonequilibrium gas/surface interaction for simulation of charring carbon ablators can be performed using an implicit approach. The material thermal response code used in this study is the three-dimensional version of Fully Implicit Ablation and Thermal response program, which predicts charring material thermal response and shape change on hypersonic space vehicles. The flow code solves the reacting Navier-Stokes equations using Data Parallel Line Relaxation method. Coupling between the material response and flow codes is performed by solving the surface mass balance in flow solver and the surface energy balance in material response code. Thus, the material surface recession is predicted in flow code, and the surface temperature and pyrolysis gas injection rate are computed in material response code. It is demonstrated that the time-lagged explicit approach is sufficient for simulations at low surface heating conditions, in which the surface ablation rate is not a strong function of the surface temperature. At elevated surface heating conditions, the implicit approach has to be taken, because the carbon ablation rate becomes a stiff function of the surface temperature, and thus the explicit approach appears to be inappropriate resulting in severe numerical oscillations of predicted surface temperature. Implicit coupling for simulation of arc-jet models is performed, and the predictions are compared with measured data. Implicit coupling for trajectory based simulation of Stardust fore-body heat shield is also conducted. The predicted stagnation point total recession is compared with that predicted using the chemical equilibrium surface assumption

Ablation↗
NASA NTRS2015

3D Multifunctional Ablative Thermal Protection System

NASA is developing the Orion spacecraft to carry astronauts farther into the solar system than ever before, with human exploration of Mars as its ultimate goal. One of the technologies required to enable this advanced, Apollo-shaped capsule is a 3-dimensional quartz fiber composite for the vehicle's compression pad. During its mission, the compression pad serves first as a structural component and later as an ablative heat shield, partially consumed on Earth re-entry. This presentation will summarize the development of a new 3D quartz cyanate ester composite material, 3-Dimensional Multifunctional Ablative Thermal Protection System (3D-MAT), designed to meet the mission requirements for the Orion compression pad. Manufacturing development, aerothermal (arc-jet) testing, structural performance, and the overall status of material development for the 2018 EM-1 flight test will be discussed.

Composite↗
NASA NTRS2012

Flowfield Analysis of a Small Entry Probe (SPRITE) Tested in an Arc Jet

A novel concept of small size (diameter less than 15 inches) entry probes named SPRITE (Small Probe Re-entry Investigation for TPS Engineering) has been developed at NASA Ames Research Center (ARC). These flight probes have on-board data acquisition systems that have also been developed in parallel at NASA ARC by Greg Swanson1. Flight probes of this size facilitate testing over a wide range of conditions in arc jets available at NASA ARC, thereby fulfilling a 'test what you fly' paradigm. As indicated by the acronym, these probes, with suitably tailored trajectories, are primarily meant to be robotic flight test beds for TPS materials, although the design is flexible enough to accommodate additional objectives of flight-testing other vehicle subsystems. A first step towards establishing the feasibility of the SPRITE concept is to arc-jet test fully instrumented models at flight scale. In a follow-on to the Large-Scale Article Tests (LSAT2) performed in the 60 MW Interaction Heating Facility (IHF) in late 2008/early 2009, a full-scale model of Deep Space-2 (DS23) made of red oak was tested in the 20 MW Aerodynamic Heating Facility (AHF). There were no issues with mass capture by the diffuser for blunt bodies of roughly 15 inches diameter tested in the 18-inch nozzle of the AHF. Building on this initial success, two identical test articles - SPRITE-T1-1 and SPRITE-T1-2 (T1 indicating the choice of back shell geometry) - were fabricated, and one of them, SPRITE-T1-1, was tested in the AHF recently. Both these test articles, 14 inches in diameter, have a 45deg sphere-cone (like DS2) made of PICA bonded on to a 1/8th inch thick aluminum shell using RTV. The aft portion of the test article is a conical frustum (15deg cone angle) with LI-2200 bonded on to the aluminum shell. Each model is fully instrumented with: (a) thermocouples imbedded in plugs in the heat shield, (b) thermocouples bonded to the aluminum substructure; the thermocouples are distributed over the entire shell, and (c) a few strain gages. Data from some of the thermocouples and gages are acquired by the on-board data acquisition system (DAS), while data from the others are routed to the facility-provided DAS, thereby enabling a cross check on the in situ measurement capability. as inputs to v2.6.1 of the in-house materials thermal response code, FIAT

atmospheric entry↗
NASA NTRS2015

Code-to-Code Comparison, and Material Response Modeling of Stardust and MSL using PATO and FIAT

This report provides a code-to-code comparison between PATO, a recently developed high fidelity material response code, and FIAT, NASA's legacy code for ablation response modeling. The goal is to demonstrates that FIAT and PATO generate the same results when using the same models. Test cases of increasing complexity are used, from both arc-jet testing and flight experiment. When using the exact same physical models, material properties and boundary conditions, the two codes give results that are within 2% of errors. The minor discrepancy is attributed to the inclusion of the gas phase heat capacity (cp) in the energy equation in PATO, and not in FIAT.

ablative materials↗